Nozzle mounted camera

ABSTRACT

An inspection system comprising (a) one or more sleds, each sled comprising (i) three or more rails running lengthwise and defining a diameter and a central axis of said each sled, (ii) first and second mounts, (iii) a nozzle comprising an interface configured for connection to a hose, and (iv) one or more jets configured for communicating fluid from said hose outward; (c) a camera module comprising (i) a housing, (ii) a camera having an optical axis, (iii) one or more lights; (iv) at least one battery, (v) memory operatively connected to said camera for recording images from said camera; and (vi) front and rear members for interengaging with said first and second mounts, respectively, such that at least one of said front or rear members urges against said first or second mounts to secure said camera module to said each sled such that said optical axis is essentially coincident with said central axis.

CROSS-REFERENCE TO RELATED APPLICATION

This application is related and claims the benefit of U.S. ProvisionalApplication No. 62/845,243, filed May 8, 2019, which is herebyincorporated by reference in its entirety.

FIELD OF INVENTION

The present invention relates to a camera system for imaging the insideof pipes, and, more specifically, to a nozzle-mounted camera forinspecting municipal pipes.

BACKGROUND

Most municipalities contain a vast network of storm and sewer pipes,often representing the oldest infrastructure in the community.Periodically, these pipes must be inspected for problems such as cracks,blockage, build-up, and root infiltration. To this end, it is common fora device such as a pipe crawler or push camera to be introduced into thepipe to perform the inspection. Although effective in obtaining detailedimages, using a pipe crawler is inconvenient and requires a great dealof time to set up and operate even if no problem is discovered.Furthermore, the use of pipe crawlers is frequently limited by the sizeand configuration of pipes to be entered. In this regard, often thecondition of the pipe (e.g., debris and fractures) prevents the use ofinspection devices like crawlers.

The inefficiencies associated with routine inspections are exacerbatedin situations where the pipes need to be cleaned since pipe inspectionand cleaning are typically performed by different personnel, often atdifferent times. In a typical cleaning operation, an inspection isperformed initially to determine whether the pipes are blocked. Such aninspection tends to be excessive since blockage conditions can bedetermined usually without the precision required for assessing cracksand other pipe damage. If a blockage is detected, then cleaningpersonnel must be brought in to perform an invasive cleaning operation.Once the cleaning procedure is performed, a second inspection istypically required to ensure that the blockage has been removed. Thissecond inspection requires the inspection personnel to return andperform yet another invasive inspection (which as mentioned above isexcessive in the first instance) to confirm whether the blockage hasbeen removed. If the cleaning was not sufficient, then the cleaningpersonnel must return to continue the cleaning operation, and thecleaning/inspection process is repeated yet again. Thus, in thiscleaning process, an inconvenient and excessive inspection is repeatedbetween each cleaning causing delays and driving up costs.

Therefore, there is a need for a more convenient approach to inspect andmaintain underground pipes without the time and complexity associatedwith specialized inspection techniques inherent in the use of pipecrawlers or push cameras. Although U.S. Patent Application PublicationNo. US-20140247338, herein incorporated by reference, addresses some ofthese concerns, the disclosed device lacked versatility in use withpipes of different diameter. More specifically, Applicant has identifieda need for a nozzle-mounted camera that is readily configurable for usein pipes of different sizes. The present invention fulfils this needamong others.

SUMMARY OF INVENTION

The following presents a simplified summary of the invention to providea basic understanding of some aspects of the invention. This summary isnot an extensive overview of the invention. It is not intended toidentify key/critical elements of the invention or to delineate thescope of the invention. Its sole purpose is to present some concepts ofthe invention in a simplified form as a prelude to the more detaileddescription that is presented later.

In one embodiment, an inspection system is disclosed comprising: (a) oneor more sleds, each sled comprising at least: (i) a plurality of railsrunning lengthwise and defining a central axis of each sled, (ii) atleast a first mount and a second mount, wherein the first mount definesa first engagement member for interengaging a front member of a cameramodule and the second mount comprises a second engagement member forinterengaging a rear member of the camera module; (iii) at least onenozzle comprising an interface configured for connection to a hose andone or more jets configured for communicating fluid from the hoseoutward; (b) said camera module comprising at least, (i) a housing; (ii)a camera in the housing and having an optical axis; (iii) at least onebattery; and (iv) the front and rear members for toollesslyinterengaging with the first and second engagement members,respectively, such that the optical axis is essentially coincident withthe central axis. For example, in one embodiment, at least one of thefront or rear members is biased axially and outwardly from the housingsuch that when the camera module is disposed between the first andsecond mounts at least one of the front or rear members urges againstthe first or second mounts to secure the camera module to each sled.

One aspect of one embodiment of the present invention is the ability ofthe camera module to be configured toollessly with different sleds. Thatis, in one embodiment, the sleds are interchangeable with a given cameramodule without the need for tools. This allows a single camera module tobe interchanged with different sleds of different diameters toaccommodate different pipe sizes.

In addition to the inter-engagement of the first and second engagementmechanisms with the front and back members respectively providing fortoolless sleds interchangeability, the mechanism also provides forself-leveling. That is, in one embodiment, the first and secondengagement mechanisms rotatably engage with the front and back members,respectively, such that the camera module rotates relative to the sled.

Still other advantages of the present invention will be apparent tothose of skill in the art in light of the specification below.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a perspective view of one embodiment of the nozzle-mountedcamera system of the present invention.

FIG. 2 shows a side view of the system of FIG. 1.

FIG. 3 shows a side view of the system of FIG. 1 with the camera moduledisengaged from the rear amount of the sled.

FIG. 4 shows a front view of the camera module of the system of FIG. 1.

FIG. 5 shows a perspective review of the camera module of the system ofFIG. 1.

FIG. 6 shows a perspective view of the bottom of the camera module thesystem of FIG. 1, revealing the charging coil located at the bottom ofthe camera module.

FIG. 7 shows a charger disposed in receiving notches of one embodimentof the sled.

FIG. 8 shows the same charger received within the rails of anotherembodiment of the sled, smaller than the sled shown in FIG. 7.

FIG. 9 shows one embodiment of the wheel extensions for the sled shownin FIG. 7.

FIG. 10 shows one embodiment of a pressurizer for pressurizing thecamera module.

FIG. 11 shows a rear perspective view of one embodiment of the sled ofthe present invention.

FIG. 12 shows a perspective view of the camera module being installedinto a sled with the rear member in the retracted position.

FIG. 13 shows the camera module and installed position in the sled withthe rear member in the extended position and interengaged with thesecond mount.

FIG. 14 shows a close up of the front portion of the camera module beingmade with the first mount.

FIG. 15 shows the front portion of the camera module mated with thefirst mount.

DETAILED DESCRIPTION

Referring to FIGS. 1-3, one embodiment of the inspection system 100 ofthe present invention is disclosed. The system 100 comprises (a) one ormore sleds 110, each sled 110 comprising a plurality of rails 115 (inthis embodiment three) running lengthwise and defining a central axis116 of each sled. The sled also comprises a first mount 111 and a secondmount 112, wherein the first mount 111 defines a first engagement member113 for interengaging a front member 121 of a camera module 120 and thesecond mount 112 comprises a second engagement member 114 forinterengaging a rear member 122 of the camera module. Referring to FIGS.1 and 11, the system 100 also comprises at least one nozzle 130comprising an interface 131 configured for connection to a hose (notshown) and one or more jets 132 configured for communicating fluid fromthe hose outward.

The system 100 also comprises the camera module 120 comprising at leasta housing 125 in a number of components contained in the housing, suchas, for example, a camera (not shown) having an optical axis 123, atleast one battery (not shown), and memory operatively connected to thecamera for recording images from the camera. In one embodiment, thecamera module 120 also comprises one or more lights 124 in the housing(see FIG. 4). In this particular embodiment, the one or more lights 124comprises a ring of LED lights, although other embodiments are possiblesuch as, for example, individual/discrete LED lights which may beoutside the housing 125.

The camera module also comprises the front and rear members 121, 122 forinterengaging with the first and second engagement members, 112, 114,respectively. In one embodiment, at least one of the front or rearmembers is biased axially and outwardly from the housing such that whenthe camera module is disposed between the first and second mounts atleast one of the front or rear members urges against the first or secondmounts to secure the camera module to the sled such that the opticalaxis is essentially coincident with the central axis.

Details of the product features and method steps are discussed ingreater detail below.

An important aspect of one embodiment of the present invention is theability of the camera module to be configured toollessly with differentsleds. That is, in one embodiment, the sleds are interchangeable with agiven camera module without the need for tools. This allows a singlecamera module to be interchanged with different sleds of differentdiameters to accommodate different pipe sizes.

In one embodiment, the toolless interchange of the camera module withdifferent sleds is achieved by virtue of the camera module beingresiliently held between the first and second mounts. This can beachieved in different ways. For example, in one embodiment, portions ofthe camera module are biased outwardly to urge against the first orsecond mounts to hold the camera module in position in the sled.Alternatively, the sled may be configured with biased mounts toessentially squeeze the camera module to hold it in place. In oneembodiment, the rear member is biased axially and outwardly from thecamera module. In one embodiment, the rear member has a retractedposition 301 and an extended position 302 as shown in FIGS. 3 and 2respectively. As shown in FIG. 2, when the rear member 122 is in itsextended position 302, it urges against the second mount 112 to forcethe front member 121 against the first mount 111, thereby securing thecamera module between the first and second mounts.

In one embodiment, the rear member comprises a retention mechanism tolock the rear member in the retracted position to facilitateinstallation/removal from the sled. Specifically, as shown in FIG. 3, tofacilitate installation of the camera module 120 in the sled 110, therear member is held in the retracted position. Once the camera module ispositioned between the first and second mounts, the rear member isreleased from its retracted position and allowed to extend toward itsextended position to provide an urging force against the second mount asdescribed above. In one embodiment, the retention mechanism isconfigured such that a partial revolution of the rear member relative tothe camera module engages/disengages the rear member from the retractedposition. For example, a user may push the rear member in to compressthe resilient means (e.g., spring, gas compression cylinder, etc.), andthen rotate the rear member slightly (e.g. ⅛-¼ rotation) to lock therear member in the retracted position. Those of skill in the art willunderstand different embodiment of such a mechanism in light of thisdisclosure and requires, including, for example, a pin and slotconfiguration. In one embodiment, the retention mechanism functions torelease the rear member from the retracted position in the oppositemanner in which it is retained—i.e. a counter rotation. Rather than arotation mechanism, the retention mechanism may comprise a latchmechanism in which the rear member is pushed forward and latched in theretracted position. Releasing the rear member in such an embodimentwould involve actuating the latch. Still other mechanisms will be knownto those of skill in the art.

The front and rear members are received in the first and secondengagement members, respectively. Again, variations in the configurationof the front and rear members and the first and second engagementmembers will be obvious to those of skill in the art in light of thedisclosure. In one embodiment, the second engagement member comprises arecess to receive the rear member. For example, referring to FIGS. 12and 13, a recess 1201 is defined in the second mount 112. In thisparticular embodiment, there also channels 1202 leading to recess 1201to help channel the rear portion 122 into the recess 1201. While FIG. 12shows the rear member 122 in its retracted position, FIG. 13 shows therear member 122 and its extended position and received by the recess1201.

Referring to FIGS. 14 and 15, one embodiment of the engagement mechanismbetween the front member 120 and the first engagement member 111 isshown. In this particular embodiment, the first mount comprises a firstkey 1401, and the front member comprises a second key 1402. The keys areconfigured such that the first and second keys interengage with anurging force provided by the rear member as described above toessentially lock the front member 120 into the first mount 111 as shownin FIG. 15. Such an inter-engagement prevents the camera module frommoving laterally with respect to the central axis portion.

Alternatively, rather than keyways as shown in FIGS. 14 and 15, FIG. 11shows an embodiment of the first engagement member 1101 of the firstmount 1102 comprising walls 1103 to restrict rotation of the cameramodule once inserted in the first mount 1102.

The toolless interchangeability of the sleds with the camera moduleprovides for versatility unmatched in conventional devices. In oneembodiment, the system 100 comprises at least two sleds, a first sledand a second sled, the first and second sleds having differentdiameters. For example, in one embodiment, the first sled of isconfigured for a 6-inch pipe, and the second sled is configured for an8-inch pipe. Although the diameters of the sleds may differ, in oneembodiment, the first and second mounts of the first and second sledshave identical first and second engagement members, such that the firstand second sleds are interchangeable with the camera module.

Furthermore, to further increase the versatility of the system 100 toaccommodate pipes of different sizes, in one embodiment, the system alsocomprises one or more wheel assemblies 901 configured for attachment tothe rails of the second sled as shown in FIG. 9. Specifically, in oneembodiment, the wheel assemblies 901 comprises a bracket 902 to whichwheels 903 are attached. In one embodiment, the bracket 902 comprisesfastener openings 904 which have the same pattern as the fasteneropenings 905 on the rails 115 as shown in FIG. 1. This configurationallows a bracket 902 to be attached readily to each rail.

In addition to the inter-engagement of the first and second engagementmechanisms with the front and back members respectively providing fortoolless sleds interchangeability, the mechanism also provides forself-leveling. That is, in one embodiment, each sled comprises aself-leveling mechanism to allow the camera module to self level. Morespecifically, the first and second engagement mechanisms rotatablyengage with the front and back members, respectively, such that thecamera module rotates relative to the sled. Although various embodimentsof self-leveling are possible, in one embodiment, the front membercomprises an annular member 1403 which is rotationally connected to thecamera module 120 as show in FIG. 14, such that when the annular memberis interengaged with the first engagement member 113, the camera modulerotates relative to the first mount 111. In one embodiment, the rearmember 122 is circular and is received in a circular recess 1201 asshown in FIG. 12, allowing the rear member to rotate within the recess1201. To facilitate self-leveling, in one embodiment, the camera moduleis configured such that a majority of its weight is below the opticalaxis such that the camera self-levels when connected to each sled. Stillother embodiments of the self-leveling mechanism will be understood bythose of skill in the art in light of this disclosure.

An important feature of one embodiment of the present invention is thatthe housing of the camera module has a very few breaches—i.e. openings.More specifically, the camera module is been designed with minimalbreaches to compromise its interior, which often needs to be positivelypressured to resist water infiltration.

In one embodiment, wireless transmission is used. For example, in oneembodiment, the camera module comprises a wireless transmitter fortransmitting images in the memory to an external receiver. For example,the wireless transmitter may be a Wi-Fi wireless transmitter. Such afeature is beneficial and that after the devices propelled up the pipein question, the images from the camera can be downloaded wirelessly forreview to a tablet/computer/smart phone/or other wirelessly connecteddevice to review the condition of the pipe. In one embodiment, thewireless devices are configured to save certain screenshots along withdocumentation as to the position of the image for documentationpurposes. Wirelessly communicating this information is a feature of thepresent invention, although not necessary, and provides a convenient wayto view images without having to open up in any way the device.

Although wireless communication of the images is preferred, it is notessential. Indeed, in one embodiment, the device is configured with acommunication port to download images via a cable. More specifically,referring to FIG. 5, one embodiment of the camera module 120 is shownwith a port 501 for a cable connection (i.e. USB or mini USB) to thememory within the camera module 120. In this particular embodiment, theport comprises a cap 502 which is screwed to seal the port ofcontamination or loss of pressure from the camera module 120 asdescribed below.

In keeping with minimizing breaches in the camera module housing 125, inone embodiment, the camera module comprises a charging coil operativelycoupled to the battery, the charging coil being configured for inductivecoupling with an external charger to charge the battery. Specifically,referring to FIG. 6, one embodiment of the charging coil 601 can be seenthrough the translucent camera module housing 125. In this particularembodiment, the charging coil 601 is disposed at the bottom 120 a of thecamera module 120. Such a configuration provides for important benefits.For example, in one embodiment, the wireless charging allows the batteryof the camera module is to be charged without being plugged in or in anyway disassembled from the sled. To this end, in one embodiment, thesystem comprises a charger 801 having a form factor such that thecharger fits between adjacent rails 802, 803 of the smallest sled 804 asshown in FIG. 8. In another embodiment, two rails 702, 703 areconfigured with notches 704 for receiving the charger 801 such that thecharger is supported by the rails 703, 702 and disposed between thecamera module and the two rails.

In keeping with the objective to minimize openings in the camera modulehousing, in one embodiment, the module comprises an internal pressuresensor to indicate when the pressure in the camera module is below apredetermined pressure.

Maintaining a positive pressure within the housing 125 of the cameramodule 120 is essential for ensuring that moisture/water does notpenetrate the housing when the housing is submerged in liquid. In oneembodiment, the internal pressure sensor is operatively connected to theone or more lights 124 is shown in FIG. 4, such that when the pressurein the camera module is below a predetermined pressure, the one or morelights turn on/off in a predetermined pattern. It should be understoodthat the predetermined pattern can take different forms. For example, inone embodiment, the predetermined pattern comprises lights 124 flashingon and off. Alternatively, the predetermined pattern may compriseturning on only a portion of the one or more lights. Regardless, such anobvious indication that the camera module is under pressurized is animportant indication for a user. Such an indication can provide criticalinformation to the user. For example, such information may be used todetermine whether the device may be used for a wet or dry environment.

Alternatively, such information may prompt the user to pressurize thecamera module. To that end, the user may pressurize the camera module120 using a pressurization device 1001 such as that shown in FIG. 10. Insuch an embodiment, the pressurization device 1001 may comprise a quickconnect 1002 which is adapted for connection to a valve nipple 503 isshown in FIG. 5. Such connections are well known in the art and will notbe described in detail herein. It is worthwhile to mention however thatthe valve 503 is accessible from the exterior of the housing.

In yet another embodiment in keeping with minimizing the breaches of thehousing 125, the on-off switch for the camera may be disposed externalto the housing and comprise a piezo switch which is turned on/off byfinger pressure on the switch. Such a configuration not only minimizeseffects from contamination, but also minimizes power required to turnthe device on and off.

Referring back to FIG. 1, the nozzle 130 is generally well-known orotherwise obvious to those of skill in the art in light of the presentdisclosure. Suffice to say, the nozzle 130 functions to convey thecamera module 120 down a pipe by virtue of pressurized water beingexpelled from the jets 132 (as shown in FIG. 11). Such nozzles are wellknown in the industry, but are used conventionally for cleaning thepipe, and not for conveying the camera down the pipe as disclosedherein. Indeed, one advantage of the present invention is thatconventional nozzles can be adapted readily to carry the camera module120 of the present invention. Typically, a nozzle comprises a body 134to support the jets 132 and adapter 131. The adapter 131 may be anycommercially-available hose coupling or similar device. Likewise, thehose (not shown) may be any commercially-available hose used in the pipecleaning industry. Although it is generally preferred to pressurize thehose with water and expel the water through the jets 132 to propel thedevice down the pipe, other embodiments are possible. For example,rather than water, the hose can be pressurized with air such that airpropels the nozzle down the pipe.

Although conventional nozzles may be used to practice the presentinvention, it should be understood that applicant anticipates nozzlesbeing optimized for carrying camera systems. For example, such nozzlesmay be optimized to minimize lateral spray which may interfere with theimaging process. In this respect, the jets 132 can be configured todirect the spray of water axially and thus propel the nozzle moreefficiently. Still other enhancements and optimizations of the nozzle130 will be obvious to those of skill in the art in light of thisdisclosure.

While this description is made with reference to exemplary embodiments,it will be understood by those skilled in the art that various changesmay be made and equivalents may be substituted for elements thereofwithout departing from the scope. In addition, many modifications may bemade to adapt a particular situation or material to the teachings hereofwithout departing from the essential scope. Also, in the drawings andthe description, there have been disclosed exemplary embodiments and,although specific terms may have been employed, they are unlessotherwise stated used in a generic and descriptive sense only and notfor purposes of limitation, the scope of the claims therefore not beingso limited. Moreover, one skilled in the art will appreciate thatcertain steps of the methods discussed herein may be sequenced inalternative order or steps may be combined. Therefore, it is intendedthat the appended claims not be limited to the particular embodimentdisclosed herein.

What is claimed is:
 1. An inspection system comprising: one or moresleds, each sled comprising at least: a plurality of rails runninglengthwise and defining a central axis of said each sled, at least afirst mount and a second mount, wherein said first mount defines a firstengagement member for interengaging a front member of a camera moduleand said second mount comprises a second engagement member forinterengaging a rear member of said camera module; at least one nozzlecomprising an interface configured for connection to a hose and one ormore jets configured for communicating fluid from said hose outward;said camera module comprising at least, a housing; a camera in saidhousing and having an optical axis; at least one battery; and said frontand rear members for toollessly interengaging with the first and secondengagement members, respectively, such that the optical axis isessentially coincident with the central axis.
 2. The system of claim 1,wherein said at least two sleds comprises at least two sleds, a firstsled and a second sled, said first and second sleds being configured forpipes having different diameters.
 3. The system of claim 2, wherein saidfirst and second mounts of said first and second sleds have identicalfirst and second engagement members, such that said first and secondsleds are interchangeable with said camera module.
 4. The system ofclaim 2, wherein a first sled of said two sleds is configured for a6-inch pipe, and a second sled of said two sleds is configured for an8-inch pipe.
 5. The system of claim 2, further comprising one or morewheel assemblies configured for attachment to said rails of said secondsled.
 6. The system of claim 1, wherein at least one of said front orrear members are biased axially and outwardly from said housing suchthat when said camera module is disposed between said first and secondmounts at least one of said front or rear members urges against saidfirst or second mounts to secure said camera module to said each sled.7. The system of claim 6, wherein said rear member is biased axially andoutwardly from said camera module.
 8. The system of claim 7, whereinsaid rear member has a retracted position and an extended position,wherein said rear member urges against said second mount to thereby urgesaid front member against said first mount, thereby securing said cameramodule between said first and second mounts.
 9. The system of claim 7,wherein said second engagement member comprises a recess to receive saidrear member.
 10. The system of claim 7, wherein said rear membercomprises a retention mechanism to lock said rear member in saidretracted position to facilitate installation/removal from said sled.11. The system of claim 10, wherein said retention mechanism isconfigured such that a partial revolution of said rear member relativeto said camera module engages/disengages said rear member from saidretracted position.
 12. The system of claim 6, wherein said first mountcomprises a first key, and said front member comprises a second key. 13.The system of claim 12, wherein said first and second keys interengageto prevent said camera module from moving laterally with respect to saidcentral axis portion
 14. The system of claim 1, wherein each sledcomprises a self-leveling mechanism to allow said camera module to selflevel.
 15. The system of claim 14, wherein the interengagement betweensaid rear member and said second engagement member allows for rotationalmovement between said camera and said nozzle.
 16. The system of claim15, wherein said front member comprises an annular member which isrotationally connected to the camera module, such that when the annularmember is interengaged with the first engagement member said cameramodule rotates relative to said first mount.
 17. The system of claim 15,wherein said camera is configured such that a majority of its weight isbelow said optical axis such that said camera self-levels when connectedto said each sled.
 18. The system of claim 1, wherein said camera modulecomprises memory in said housing operatively connected to said camerafor recording images from said camera
 19. The system of claim 18,wherein said camera module comprises a wireless transmitter fortransmitting images in said memory to an external receiver.
 20. Thesystem of claim 19, wherein said wireless transmitter is a Wi-Fiwireless transmitter.
 21. The system of claim 1, wherein said cameramodule further comprises a charging coil operatively coupled to saidbattery, said charging coil being configured inductive coupling with anexternal charger to charge said battery.
 22. The system of claim 21,wherein said charging coil is disposed on the bottom of said cameramodule.
 23. The system of claim 21, further comprising a charger havinga form factor such that said charger fits between adjacent rails of thesmallest one of said one or more sleds.
 24. The system of claim 23,wherein two rails of said 3 or more rails comprises notches forreceiving said charger such that charger is disposed between said cameramodule and said two rails.
 25. The system of claim 1, further comprisingan internal pressure sensor to indicate when the pressure in said cameramodule is below a predetermined pressure.
 26. The system of claim 25,wherein said internal pressure sensor is operatively connected to saidone or more lights such that when the pressure in said camera module isbelow a predetermined pressure, said one or more lights turn on/off in apredetermined pattern.
 27. The system of claim 26, wherein saidpredetermined pattern comprises flashing on and off.
 28. The system ofclaim 26, wherein said predetermined pattern comprises turning on only aportion of said one or more lights.
 29. The system of claim 1, whereinsaid camera module further comprises a valve accessible from theexterior of said housing.
 30. The system of claim 29, further comprisinga pressurizer having a quick connect for interengaging said valve topressurize said camera module.
 31. The system of claim 1, wherein saidcamera module also comprises an on-off switch.
 32. The system of claim31, wherein said on-off switch is a piezo switch which is turned on/offby finger pressure on the switch.
 33. The system of claim 1, whereinsaid nozzle is connected to said second mount.